TiAL R770 & S605 - Performance Parts & Tuning For Audi .
TiAL R770 & S605Installation notesTIAL Sport !!!!TiALsport.comRevision 2
TiAL SportCaution!The components in this package may require additional parts to be sourced or fabricated for the installation. Due to the number of aftermarket components available for the Audi / VW 2.7T Platforms, it is impossible to guarantee that the following components will be compatible with third party parts and systems.The installation of this product requires the expertise of a knowledgeable installer with the resources to diagnose and solve any installation and/or performance issues that may arise. It is important to perform any maintenance or repairs and confirm the perfect mechanical operating condition of the motor and vehicle beforeundergoing the TiAL turbo charger upgrade. Depending on operating parameters established by the tuner, thissystem is capable of creating conditions that will not be sustainable by the engine’s internal components (stock rods are the first weak link) without further upgrades. Serious engine damage can result if care, detailedplanning and testing is not exercised.Please Note: ** This is not intended to be a step-by-step instruction manual. **Installation Notes!1
TiAL SportCheck List!Before the disassembly of the recipient vehicle, please familiarize yourself with the kit’s components.Ensure that the entirety of the package is included, and that you have all the tools, ability and OEM fluids andgaskets to finish the installation. In the following section titled Component List, please ensure that you havethe full inventory of items.Tools:"Please read through the Installation notes to make sure that you are equipped to perform all the stepsneeded for a complete installation. A flat & semi circular rasping file may be needed, often these can be twosides of the same tool. A cut off wheel will be needed to trim a turbocharger discharge tube 1.5”.OEM Gaskets:"Gaskets and crush rings available as OEM parts are not included as part of the basic installationpackage."""Turbine Inlet Seal Ring: Part# 078 145 039 is not included. 2 are needed, one for each turbo.12mm AL Crush Washers Part# XXX XXX XXX. 4 will be needed.Turbine Housing - Down-pipe Gasket ( s605 Only, R770 No gasket needed ) Part#OEM Fluids"""Coolant, G12, or G12 and Distilled water.Power Steering FuildEngine Oil: 6.1 Quarts.Installation Notes!1
TiAL SportComponent ListTurbocharges1 Driver-side turbo charger1 Passenger-side turbo chargerTiAL developed turbochargers for the Audi 2.7T Engine!Each turbocharger:""1 TiAL High Pressure Actuator with AN fitting forleak free actuator pressure control. (Assembled)""1 -4 AN to 1/8th NPT fitting1 AL CNC Actuator bracket. (Assembled)Driver-sidePassenger-sideInlet tubingCNC Mandrel bent Stainless Steel Inlet-tubing.1 Driver-side inlet1 Passenger-side inletDriver-sidePassenger-sideInstallation Notes"1
TiAL SportLines and FittingsTurbo Coolant Supply1 Driver-side line with silicon fire sleeve"(24” in length )1 Passenger-side line with silicone fire sleeve"( 12” in length )x2 CNC Aluminum Banjo Fittings !x4 12 mm CNC Stainless-steel Banjo boltsx8 12 mm Copper Crush-washersTurbo Oil Supply1 Driver-side High pressure oil supply line"(12” braided length, 90 degree fitting )1 Passenger-side High pressure oil supply line"(15”” Braided length, 45 degree fitting )x2 -4 AN - 10 mm banjo fittingsCompressor Pressure Signal Lines1 Driver-side signal line"( 18” braided length, Straight - 90 degree )1 Passenger-side signal line"( 22” braided length, Straight - 90 degree )1 -4 AN 3-way Tee1 -4 AN High pressure push-loc hose w/fittingWaste-gate Actuator Lines1 Driver-side actuator line"( 22” braided length, Straight - 90 degree )1 Passenger-side actuator line"( 24” braided length, Straight - Straight )1 -4 AN 3-way Tee1 -4 AN high pressure push-loc hose w/fittingInstallation Notes"2
TiAL SportHoses & ClampsInlet Tube CouplingsBlack (Blue*) (Red*) - *Optioned at time of order.x2 2.25” (I.D.) 5 ply High temp silicone hump-hosesx4 2.62” (I.D.) Stainless-steel t-bolt clamps2.25” Inlet Hump-hose2.00” Compressor outlet hoseCompressor Outlet Couplingsx2 2.00” (I.D.) 4 ply High temp silicone couplersx4 2.38” (I.D.) Stainless-steel t-bolt clampsStainless-steel t-bolt clampsRecirculation Couplingsx2 TiAL High temp recirculation couplingsInstallation Notes"3
TiAL SportHardwareManifold - Turbine Housing!Each turbocharger:"x3 SHCS 10 mm x 1.5 x 25mm boltsTurbine - Exhaust Downpipe ( R770 )!For each R770 Turbocharger"""x2 Stainless SteelR770 Divorced Flow Exhaust down-pipe flangex4 10mm x 1.25 x 25mm BoltsTurbine - Exhaust Down-pipe ( s605 )!Each S605 Turbocharger:""x2 10mm x 1.5 Short Stainless-steel hex-head boltsx2 10mm x 1.5 Long Stainless-steel hex-head boltsOil Drain flange!Each turbocharger:""x2 6 mm Stainless-steel boltsx2 6 mm Stainless-steel washersSeals & GasketsCompressor inlet Threshold Seal!Viton O-rings2x Viton O-ring in inletTurbo oil drain flange!2x Flexible gasket sealOil drain flange gasket & Stainless-steel hardwareInstallation Notes"4
TiAL SportDisassemblyRemove:""""Remove the left and right turbochargers from the exhaust manifolds.TIP* using a torch, use liberal amounts heat directed at the turbine housing near the mounting bolts. Carefully add a"penetrating lubricant to the warm parts to help with any seized or difficult bolts."Disconnect the Oil supply, Oil Drain, Coolant Supply, Coolant Return lines.""Remove the Oil supply lines from the oil distribution block.(no. 27)"Keep the 10 mm banjo bolts (no. 6) These will be used to secure the new Turbo oil supply lines.""Remove the driver-side and passenger-side water return lines (no. 15, 16)"(these lines originate at the turbo and meet to a tee behind & under the intake manifold)""!Remove the compressor signal lines (no. 28,29)!Remove the actuator pressure lines (no. 28,29)Do not remove the coolant supply lines from behind the motor-mount brackets. ( no. 14, 17)Oil supply linesWater return linesActuator & Compressorsignal linesInstallationtion Notes"Notes5
TiAL SportPreparationsEngine Support Modifications."Slight modifications to the Engine Support bracket will allow for greater clearance with the 2.25” diameter stainlesssteel inlet tubing during installation and removal. Some vehicles may require more or less chamfering of the bracket edges.This modification will not compromise the integrity of the support. It will not prevent the reinstallation of stock components ata later time.Engine Support Left and Right Locations on motor.Passenger-side Engine support bracket modificationUsing a flat file or a die-grinder with the appropriate AL cutting bit, chamfer the corner of the engine mount bracket.(as pictured)Chamfer the edge, 6-10 mm in at 45 degrees.Installation Notes"6
TiAL SportDriver-side support modificationWith a die grinder or semicircular file, remove the casting flash from the driver-side engine mount bracket.Lightly remove any casting flash if any is present.Confirm fitment & Clearance of inlet tube after installingturbo charger.Coolant supply linesPassenger-side turbo charger coolant supply line modificationThe passenger-side turbo charger supply line has a mounting tab which will need to be removed for the installation of theTIAL turbochargers. Using a small cutting tool, very carefully remove the tab from the tubing, file away any burrs.Mark the bracket to be removed with a line near the tubingUsing a small cut off wheel, carefully remove the mountingbracket.Installation Notes"7
TiAL SportTurbo charger compressor outlet tube modificationDriver-side modificationsThe driver-side compressor outlet tube will need 35mm (1.50”) removed from the inboard length. This is the side of the tubethat will join to the compressor outlet. Using a band saw, or cutoff wheel, remove 35-mm (1.50”) from its lengthOil Drain Tube Modification ( depending on configurations)If your turbo configuration is one that uses M8 Bolts for the CHRA oil drain flange, then the 6.5mm bolt holes in the factorydrain tubes will have to be enlarged. Remove the Oil drain tubes from the upper oil pan, and fixture the drain flange so thatyou can carefully enlarge the 6.5mm hole to a 8mm hole. A 5/16” empirical drill bit will be just about right. Please take care tocarefully clean and wash all parts to be free of any metal chips and burrs after you drill.Installation Notes"8
TiAL SportLayout and LinesTurbo Coolant Supply LinesRemove the two lines from the package labeled “TiAL Sport Audi 2.7 Water Kit”.Find the package containing:!x2 CNC Aluminum Banjo Fittings"x4 12 mm CNC Stainless-steel Banjo bolts"x8 12 mm Copper Crush-washersUsing a small amount of brake-clean or hand soap, lightly lubricate the barbed section of the AL fittings. Press the fittings fullyinto the reinforced line. Lightly fix an Oetiger style crimp clamp to the line around the barbed fitting.Turbo Oil Supply LinesOpen the package labeled “TIAL Sport Audi 2.7 Oil Kit”"Prepare the oil supply lines for installation - The new TiAL 2.7 Oil Kit lines are pre-assembled and hydraulicallycrimped for a leak free and reliable assembly. You can Identify the new lines by the Black Semi-translucent silicone abrasionskin over the stainless steel braid. The Banjo fitting’s nut will be tightened later, after everything is affixed to the engine blockand the lines have been routed to the turbochargers.Driver-side - 90 Degree Fitting! Fitting Orientation - Pointing inwardsPassenger-side - 45 Degree FittingInstallation Notes"9
TiAL SportWastegate PreloadThis important step is left up-to the tuner to configure according to their specific tuning philosophies and goals. Factors suchas overall desired boost, minimum boost setting, boost control method / device, and operating altitude all are factors whichneed to be considered during the setup of your TiAL S605 / R770 Turbos. Preload is measured and set on a test bench withthe appropriate pressure regulator, and a dial indicator.The “Cracking” pressure is considered the point at which the wastage arm travels .009” inch. Also defined where there is nolonger any physical preload on the wastage puck.The following table is just an ESTIMATE of the calculated set point to operation pressure relation.S605:Set Cracking pressureMinimum Operating Pressure16.5 Psi17.5 Psi ( Manifold) spike - 16.5 @ Redline18.5 Psi ( RECOMMENDED)20.9 Psi (Manifold) spike - 19 @ Redline24 Psi25.0 Psi ( manifold) spike - 24 @ RedlineR770:Set Cracking pressureMinimum Operating Pressure16.5 Psi22.5 Psi ( Manifold) spike - 17 @ Redline20 Psi ( RECOMMENDED)25 Psi (Manifold) spike - 23 @ Redline24 Psi28.0 Psi ( manifold) spike - 25 @ RedlineAfter setting the gates on both turbos to identical values, tighten the lock nuts against the linkage to prevent any change insettings. Use a green penetrating thread locker to seal the threads after they have been tightened.Installation Notes"10
TiAL SportInstallation!Bolts, Turbos, Lines, Couplers & Clamps.Inlet seal no. 13Installing the TurbochargersDriver-side TurboTurbine inlet seal ring ( PN# 078 145 039 ) Not Included"Insert a new Gas Seal Crush Ring into the turbocharger seat.Turbo-Manifold Bolts"Apply some high temperature copper based anti seize to the three 10 mm"manifold-turbo bolts and torque to 25N-M ( factory spec)Coolant Supply line"The turbo coolant supply originates from behind the engine mount bracket. Use the supplied Stainless-steel banjo"bolts and crush washers to secure this line to the turbocharger’s CHRA.Coolant Return line (Driver-side)"This line, is the 24” fire-sleeved push-loc hose. This line will originate from the outside port of the CHRA and"continue underneath the turbocharger to connect to the coolant return tee fitting. Use a light "lubricant ( silicon spray"or soap) to help with the installation the coolant hose onto the water distribution tube. Use a clamp to "secure.Oil supply line ( Driver)"Connect the line to the top of the turbocharger first, do not fully tighten until you have finished routing the line to the"oil distribution block. Connect the 10mm Banjo fittings to the oil distribution block using the original 10mm Banjo"bolts, and new 10mm AL crush washers. Make sure you leave sufficient clearance for the PCV system (spider hose)"and the main coolant return line and clamp. Once both ends are no routed, tighten all fittings to ensure a leak-free"operation. The banjo fittings connected to the Oil-Distribution-Block should be pointing upwards and slightly"rearwards in reference to the car for best fit.Oil return line"Secure the oil return line to the CHRA. Use the supplied stainless steel bolts, and oil drain gasket."If the braided line is misaligned to the point of being crimped, some small adjustments to the oil drain tube will need"to be made. If the CHRA is supplies with M8 Bolts, then the 6.5mm hole in the oil drain port will have to be enlarged"to 8mm.Compressor outlet connection"Use the supplied 2.00” reinforced silicone coupler and stainless steel T-Bolt clamps to secure the intercooler inlet"tube to the turbocharger. Ensure that the inside surface of the silicone coupler is clean and free of any oil or grease."Use a solvent to prep both mating surfaces before securing the coupler with the clamp, this will help ensure you"form a strong and trouble free union.Installation Notes"11
TiAL SportPassenger-sideSame steps as Driver-side installation. Differences noted below.Coolant Return line ( passenger)"This line, is the 12” fire-sleeved push-loc hose. This line will originate from the inside port of the turbo charger CHRA"and continue up to connect to the coolant return tee fitting. This is the first line to attach to the turbocharger. Use the"supplied stainless steel banjo bolt and crush washers. Ensure that you have sufficient clearance with the"waste-gate actuator rod, and bell housing features. Use a light lubricant ( WD-40.Soap, Brake Clean) to help with"the installation the coolant hose onto the water distribution tube. Use a clamp to secure.Coolant Supply line"The turbo coolant supply originates from behind the engine mount bracket. Use the supplied Stainless-steel banjo"bolts and crush washers to secure this line to the outside port on the turbocharger CHRA.Turbine inlet seal ring ( PN# 078 145 039 )"Same as Driver-sideTurbo-Manifold Bolts"Same as Driver-sideOil supply line"Same as Driver-sideOil return line"Same as Driver-sideCompressor outlet connection"Same as Driver-sideInstallation Notes"12
TiAL SportArea to modify if oil return line is stressed.Connection to N75 Valve"Actuator and Compressor Lines!!!!Install the compressor signal line, and the waste-gate actuator lines. Route the lines paying attention to avoidmaking contact with the exhaust manifolds, and the waste-gate linkage. Before tightening any of the AN fittings,route them first with loose connections. Use the appropriate waste-gate actuator ports and compressor ports oneach turbocharger.""Join the left and right Actuator lines to each other with the supplied AN - tee.Join the left and right Waste-gate lines to each other with the supplied AN -tee.!Attach the N75 valve to the new actuation system with the supplied high pressure lines and fittings.!Make sure to tighten all -AN connections.Down-pipe installation""""Install the Exhaust down-pipes to the turbocharger turbine housings.Use a new gasket. (Audi PN#: 8D0 253 115 F) for each turbocharger. - Not IncludedThere are two different length bolts supplied, the shorter bolts are for the sides, and the longer bolts are used in thetop and bottom holes, in the turbine housing.Installation Notes"13
TiAL SportInlet-pipe installation.!!!!Before placing the motor into the vehicle, ensure that you can install and remove the inlet tubes from the compressorinlet. Prepare the two Viton rings, by lubricating them with a thick lubricant or grease. Press them into the thresholdgrove of the inlet tube. Use your fingers to ensure that the O-ring is FULLY seated into the grove beforeattempting to press it onto the compressor inlet. The initial installation might require some force."""Use the supplied 2.25” Hump hoses to connect the OEM Y-Pipe to the stainless steel inlet tubes. Secure thecoupling with the supplied stainless-steel t-bolt clamps You do not need to torque this connection much beyondfinger tight, as it is not part of the pressurized charge path.!!!!*! IF you are attempting to install the Inlet tubes after you place the engine back into the engine bay. You will need tolift the motor 3-4 inches from its final position. The motor mount nuts will have to be removed to allow for thisupward travel. The Tubes will be able to be inserted as they will now clear the frame rails, allowing you to push thetubes in as you rotate them into place.""*! For customers with an RS4 Y-pipe. The Correct coupler will be a 2.75-2.225 transition coupler. In addition 0.75”will need to be removed from the top end of each inlet pipe. Please contact us for the correct silicone part.Recirculation BBV’s"With the Inlet pipes installed, use the 1” silicone elbows to connect to the recirculation circuit.""*! An X-1 or other intake system is required for proper fitment. Otherwise modification to airbox will need to bemade.Installation Notes"14
The components in this package may require additional parts to be sourced or fabricated for the in-stallation. Due to the number of aftermarket components available for the Audi / VW 2.7T Platforms, it is im-possible to guarantee that the following components will be compatible with third party parts and systems.
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Sikka [14] recently observed a 120"J0fracture strain in a powder-metallurgy TiAl alloy creep tested at 138 MPa and 760"C. The steady-state creep rate was measured to be approximately 6 x 10-7 s-l. To the authors' knowledge, 760 C is the lowest temperature at which extended ductility has been observed in a TiAl alloy. In the present paper, we
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